Electrical connector and method of making same.



Patented June 5, I900. T. J. MCTIGHE.

ELECTRICAL CUNNECTOR AND METHOD OF MAKING SAME.

(Application filed Mar. 80, IQQO.) (No Model.)

I V l 7 xv/5.518753 UNITED STATES PATENT OFFICE.

THOMAS J. MCTIGHE, NEW YORK, N. Y.

ELECTRICAL CO NNE CTOR AND METHOD OF MAKING SAM-E.

srncmcarxox forming art of Letters Patent no. 650,862, time runes, 1900.

Original application filedPebruary 27, 1900, Serial No. 6,719. Divided and tlillapplieatlon filed larch 30, 1900. Serial No.

10,839. (Ho-model.)

To all whom it may concern:

Be it known that I, THOMAS J. MoTIoHn, a citizen of the United States, residing at New York, in the county of New York-and State of New York, have invented certainnew and useful Improvements in .Electrical Connectors and Methods of Making the Same; and I do hereby declare the following to be a f nu, clear, and exact description of the invention, such as will enable others skilledin the art to which it appertains to make and use the same, this application being a division of my application, Serial No. 6,713, filed February 27, 1900.

This invention relates to a novel method of splicing or connecting electrical conductors,

whereby two sections of conductor of any carrying capacity can be expeditiously and permanentlyspliced together, forming a compact and solderless jcint of lower resistance per unit of length than the'conductor itself and having all the mechanical strength required.

The invention consists in thenovel method of splicing electrical conductors by swaging and cold-welding and in the novel character of splice or joint produced thereby; both as hereinafter fully described, and set forth in the claims.

1n the accompanying drawings, which form part of this specification, Figure 1 is a side elevation of the ends of two conductor-sec- 1 tions with my splicing-sleeve in section prior to compression. Fig. 2 is an end view of the same, showing a pair of compressing-dies ready for application of pressure. Fig. 3 is a similar view to Fig. 1, showing the completed jointafter powerful compression. Fig.

4 isan end view of Fig. 2, but with the dies brought nearly together. Fig. 5 is a side view, partly sectional, showing a modified form of sleeve before compression. Fig. 6 is a similar view after compression; and Fig. 7 is a side view, partly sectional, of a completed joint of modified character.

Referring to the drawings, my invention is carried out in the following manner: I square oflf the'ends A B of the conductor-sections which are to be spliced,.strip the insulation (if any) for a few inches, clean the ends, and

50. with clean inner surface.

insert them in a sleeve 0, of ductile metal, The cross-section is preferably oval outside, as in Fig. 2, I

then inclose the sleeve 0 and conductor ends. A B between suitable dies D D and apply a powerful pressure to the latter, tending to bring them'together, as at Fig. 4. The sleeve C yields under the pressure, becoming smaller in diameter and thicker in the wall, while the pressure is transmitted inwardly upon theconductor ends A B, forcing them into a compact mass-that is, the great pressure brings the sleeve and inclosed conductors into a practically-homogeneousmass, the contacting surfaces of which are coherent, an effect which I call cold-welded. In the joint shown at Figs. 3 and 4 the sectional area of the sleeve is nearly double that of the conductor, while the area of surface contact between each conductor end and the sleeve is more than ten times the sectional area of the conductor. This gives a joint of extreme low resistance elec-' trically. Mechanically, such a splice has great strength. The compression hardens and stiflE- one the metal, and the tensile strength of the joint is ample for ordinary service. By my invention I accomplish the splicin in a few moments, remove but a few inches of insulation, and use no solder or heat.- The operation is the same for'all sizes of conduc- -tors.

Any convenient or suitable source of pressure is applicable, such as hydraulic or screw press or a wedge-press. I, however, prefer the hydraulic jack-press, which while capable of giving great pressures is still quite portable and can be carried readily along the line of work for coupling the conductor-sections.

Where great tensile strength is required in the splice, I so shape the sleeve 0 that when A B, as shown in Fig. 6. A similar eflect is produced in Fig. 7, where the outer dotted linesshow the original form of the sleeve, the

full lines show .the compressed sleeve and conductors, and the inner dotted lines show the constricted and compacted conductors, the same letters of reference'being used asin Figs. 5 and 6 and indicating thesame general idea. In Fig. 7, however, I leave the'abutting ends of theconductors A B practically uncompressed, thus adding to the strength by having a relatively-deep constriction between the compacted zone-and the inner end of each section.

Without exceeding the pressure easily obtainable with portahleapparatus'quite suitable for linework I can by my invention in a few minutes complete a splice on the largest conductor.

I claim- 1.. The method of splicing electrical conductors, which consists in inclosing the ends of the conductors in a ductile metal sleeve and subjecting the same to sulilcieut lateral Y pressure to cold-weld the con tooling surfaces together. 1

2. The method of splicing solid electrical conductors consisting in inserting the conductor ends into a ductile metal sleeve and cold-swaging the sleeve and inclosed conductors so as to reduce the cross-sectional area of the sleeve and conductors.

The method of splicing electrical conductors, which consists in inclosing the ends swaging down the sleeve and conductors so as to reduce their cross-sectional area and produce at their contacting surfaces interlocking projections and depressions;

4. A splice for electrical conductors, consisting of a ductile metal sleeve inclosing the ends of the conductor-sections and cold-welded thereto. 5. A splice for electrical conductors, consisting of adnctile metal sleeve inclosing the ends of the condnctorsections and cold-welded thereto, the contacting surfaces-of the conductors and sleeves having swaged interlocking projections and depressions.

In testimony whereof I have afllxed my signature in presence of two witnesses.

THOMAS J. MCTIG'HE.

Witnesses:

THOS. A. CONNOLLY; Jos. B. CONNOLLY. 

